Composite veneer including a nonwoven inner ply

ABSTRACT

A composite veneer including a cellulose outer face and a nonwoven inner ply for mounting to a curved support surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Application No.61/942,476, filed Feb. 20, 2014, the entire disclosure of which ishereby incorporated by reference in its entirety.

BACKGROUND AND SUMMARY OF THE INVENTION

The present invention relates generally to sheet veneer and, moreparticularly, to a composite veneer including a nonwoven inner ply andmethod of making same.

Decorative laminates, such as wood veneers, are popular wall coveringsin a variety of settings. One application of such wood veneers is withinaircraft passenger cabins. Traditional wood veneers often include apoplar wood inner ply positioned between wood outer faces or layers.Exemplary wood outer faces or layers include, but are not limited to,ash, bamboo, birch, cherry, hickory, mahogany, maple, oak, elm, poplar,teak, and walnut.

Wood veneers have become increasingly thinner, resulting in certainmanufacturing difficulties, often along with quality and durabilityissues in the final product. For example, traditional veneers includinga poplar wood inner ply often experience telegraphing, where the woodpattern from the inner ply shows through (e.g., as bumps and lines) inthe finished surface of the outer face or layer. Such telegraphing mayresult from different shrinkage amounts of the veneer layers, often dueto different relative moisture contents. It is therefore desired toprovide a composite veneer that reduces telegraphing.

Traditional veneers including a poplar wood inner ply may also besusceptible to moisture absorption. Degradation results from moisturebuildup, leading to the decomposition of traditional wood inner ply. Theresult is the buildup of CO₂ gas, which may attack the finish surfacelayer resulting in checking, hazing and delamination. It is desirable toprovide a composite veneer that improves breathability characteristicsand prevents moisture buildup.

It is also desired to provide a wood veneer including an inner ply thatprovides a flexural modulus lower than a traditional wood inner ply,thereby allowing the wood veneer to cover tight radiuses and curves. Itis also desired to provide such a wood veneer with notably improved burnresistance (e.g., with a zero second extinguish rate after burn).

Again, there is a need for a composite wood veneer that preventstelegraphing for improved sanding efficiency and appearance, improvesflexibility, burn resistance and stability, offers ease ofmanufacturing, especially during high torque handling, and extendsproduct life and reduces material costs.

According to an illustrative embodiment of the present disclosure, acomposite veneer includes a first outer wood face, a second outer woodface in parallel spaced relation to the first outer wood face, and anonwoven inner ply positioned between the first outer wood face and thesecond outer wood face.

In one illustrative embodiment of the present disclosure, a compositeveneer is provided. The composite veneer includes a first celluloseface, a second cellulose face in parallel spaced relation to the firstcellulose face; and a nonwoven inner ply positioned intermediate thefirst cellulose face and the second cellulose face, the nonwoven innerply formed from a plurality of polymer fibers. In one more particularembodiment of the composite veneer, the first cellulose face and thesecond cellulose face are formed of poplar wood. In another moreparticular embodiment of the composite veneer, the polymer fibers areformed of an at least partially amorphous polymer.

In a more particular embodiment of any of the composite veneersdescribed above, the polymer fibers are formed of a novoloid. In oneparticular embodiment, the novoloid fiber contains at least 85% of across-linked novolak.

In a more particular embodiment of any of the composite veneersdescribed above, the polymer is selected from the group consisting of:polystyrene, polymethylmethacrylate, polyphene sulfides, polysulfone,polyetherimide, polyetheretherketone, polyether sulfone,polyisobutylene, poly(vinyl acetate), and novoloid. In another moreparticular embodiment, the polymer fibers are formed of a polymerselected from the group consisting of: nylon, novoloid, novolac,phenolic fibers, melamines, polyesters, polypropylenes, polyethylenes,polystyrenes, polyacrylic acids, polyacrylonitrils, polyimides,polyetherimides, polyamideimides, polymethyl methacrylates,polyphenelene sulfides, aramids, polybenzimidazoles,polyphenylenebenzobizoxazoles, aromatic polyketones, polyvinyl acetates,polysulfones, polyethersulfones, polyurethanes, polyisobutylenes, liquidcrystal polymers, and poly(paraphenylene terephthalamide).

In a more particular embodiment of any of the composite veneersdescribed above, the inner ply further comprises a synthetic latex. In amore particular embodiment of any of the composite veneers describedabove, the inner ply further includes a flame retardant. In oneembodiment, the composite veneer has a zero second extinguish rate afterburn.

In a more particular embodiment of any of the composite veneersdescribed above, the nonwoven inner ply is a needle punched nonwovenmaterial.

In one embodiment, the composite veneer has a flexural modulus accordingto ASTM D790 of about 2 times lower, about 4 times lower, about 4.5times lower, about 5 times lower, or lower, or within any range definedbetween any two of the foregoing values than that of a similarlyconstructed standard three-ply veneer having a cellulose inner ply, suchas poplar. In one embodiment, the composite veneer has a bending radiusas low as about 0.20 inches parallel to wood grain. In one embodiment,the composite veneer has a bending radius as low as about 1.25 inchesperpendicular to wood grain.

In a more particular embodiment of any of the composite veneersdescribed above, the composite veneer further includes a first adhesivelayer between the first cellulose face and the nonwoven inner ply, and asecond adhesive layer between the nonwoven inner ply and the secondcellulose face. In one embodiment, the first and second adhesive layersindependently comprise an adhesive selected from the group consistingof: a phenolic glue and an acrylic melamine glue.

In another illustrative embodiment of the present disclosure, a methodof forming a composite veneer is provided. The method includes providinga first cellulose face; providing a nonwoven ply formed from a pluralityof polymer fibers; adhering the nonwoven ply to the first cellulose facewith a first glue line; pressing the first cellulose face, first glueline, and nonwoven ply in a press at elevated temperature and pressureto form a two ply composite; adhering a second cellulose face to thenonwoven ply of the two ply composite with a second glue line; andpressing the two ply composite, second glue line, and second cellulosein a press at elevated temperature and pressure to form the compositeveneer.

In one embodiment, the method further comprises slicing a log to form aplurality of sheets; splicing a first portion of the plurality of sheetswith an adhesive to form the first cellulose face; and splicing a secondportion of the plurality of sheets with an adhesive to form the secondcellulose face.

In a more particular embodiment of any of the above methods, theelevated temperature is about 350° F. In a more particular embodiment ofany of the above methods the elevated pressure is about 230 bar.

In a more particular embodiment of any of the above methods, the methodfurther includes pressing the nonwoven ply at an elevated temperatureand pressure.

In a more particular embodiment of any of the above methods, the methodfurther includes cooling the two-ply composite to room temperature.

In a more particular embodiment of any of the above methods, the methodfurther includes treating the composite veneer with a fire retardant.

In a more particular embodiment of any of the above methods, the polymerfibers are formed of a novoloid.

Additional features and advantages of the present invention will becomeapparent to those skilled in the art upon consideration of the followingdetailed description of the illustrative embodiment exemplifying thebest mode of carrying out the invention as presently perceived.

BRIEF DESCRIPTION OF THE DRAWINGS

The detailed description of the drawings particularly refers to theaccompanying figures in which:

FIG. 1 is a perspective view of an illustrative composite veneer of thepresent disclosure;

FIG. 2 is a cross-sectional view of the composite wood veneer of FIG. 1;and

FIG. 3 is a flowchart illustrating a method of manufacturing thecomposite wood veneer of FIG. 1.

DETAILED DESCRIPTION OF THE DRAWINGS

The embodiments of the invention described herein are not intended to beexhaustive or to limit the invention to precise forms disclosed. Rather,the embodiments elected for description have been chosen to enable oneskilled in the art to practice the invention.

Referring initially to FIGS. 1 and 2, an illustrative composite woodveneer 10 of the present disclosure is shown for mounting to a supportstructure, such as a wall 30 of an aircraft including a curved mountingsurface 32. The composite veneer 10 includes multiple layers including afirst outer face or layer 12, a second outer face or layer 14, and aninner ply or layer 16. A first adhesive layer 18 is positioned betweenthe first outer face 12 and the inner ply 16, and a second adhesivelayer 20 is positioned between the second outer face 14 and the innerply 16.

In the illustrative embodiment, the first and second outer faces 12 and14 each comprise a cellulose material, such as, but not limited to, ash,bamboo, birch, cherry, hickory, mahogany, maple, oak, elm, poplar, teak,and walnut. More particularly, each of the outer faces 12 and 14illustratively comprises a wood sheet, such as poplar or cherry having athickness of approximately 0.024 inches. The inner ply 16 isillustratively formed of a three-dimensional needlepunch nonwovenmaterial. The nonwoven material illustratively combines high tensilesynthetic fibers with chemical enhancement to provide advantageousthermodynamic properties in a semi-flexible, stiff isolating core. Theneedle punching provides tensile strength and controlled elongation.

The fibrous material of the nonwoven inner ply 16 illustrativelycomprises polymer fibers of suitable strength arranged in asubstantially parallel unwoven relation in a tenuous web form. Variousamorphous, partially amorphous and non-amorphous polymer fibers may beused alone or in combination within the nonwoven inner ply 16.

The first illustrative type of polymer fibers of the nonwoven inner ply16 are completely amorphous, or at least have regions that areamorphous. Non-limiting examples of polymers that are amorphous, atleast in some cases, include polystyrene, polymethylmethacrylate,polyphenelene sulfides, polysulfone, polyetherimide (e.g., Ultem® fromSABIC), polyetheretherketone, polyethersulfone, polyisobutylene,poly(vinyl acetate), novoloid (e.g., Kynol® from American Kynol), andthe like.

The second illustrative type of polymer fibers of the nonwoven inner ply16 are illustratively completely non-amorphous or only partiallyamorphous. Examples of such polymers include polyamides such as nylons,novoloid (e.g., Kynol® from American Kynol), novolacs, phenolic fibers,melamines, polyesters, polypropylenes, polyethylenes, polystyrenes,polyacrylic acids, polyacrylonitriles, polyimides, polyetherimides,polyamideimides, polymethyl methacrylates, polyphenelene sulfides,aramids (e.g., meta- or para-aramids, e.g., Kevlar® from Dupont),polybenzimidazoles, polyphenylenebenzobizoxazoles, aromatic polyketones(e.g., polyetheretherketones, polyetherketoneketones, etc.), polyvinylacetates, polysulfones, polyethersulfones, polyurethanes,polyisobutylenes, liquid crystal polymers, and poly(paraphenyleneterephthalamide).

In certain illustrative embodiments, novoloid fibers are used for thenonwoven inner ply 16. Novoloid fibers are cured phenol-aldehyde fibersmade by acid-catalysed cross-linking of metal-spun novolak resin to forma fully cross-lined, three-dimensional, amorphous network polymerstructure similar to that of thermo-setting phenolic resins. Novoloid isrecognized in the industry as a manufactured fiber containing at least85% of a cross-linked novolak, and is available as Kynol® from AmericanKynol of Pleasantville, N.Y.

A variety of technologies may be used to stabilize fibers into anonwoven matrix of fibers, including mechanically, chemically, and/orthermal bonding. More particularly, various non-woven materials may beformed by needlepunch (i.e., mechanical interlocking of fibers),chemical bonding, thermal bonding, hydro-entanglement, spun bonding,melt blown, and wet laid. These various processes may be combined toimprove the chemical resistance, mechanical attributes, and requiredmodulus, flexibility, and tensile strength for veneer core or inner ply16.

The chemical enhancement of the inner ply 16 is illustratively asynthetic latex formulated to further enhance the needle punchednonwoven material and provide additional flame retardant properties. Thethermodynamic properties of a combination of flame retardant chemicalsin the treatment provides for flame suppression to assist in the controlof thermal degradation of the cellulose veneer.

Examples of flame retardants include, but are not limited to, mineralssuch as aluminum hydroxide, aluminum oxide, aluminum trihydrate,magnesium carbonate hydroxide, magnesium hydroxide, huntite,hydromagnesite, hydrates, red phosphorus, boron compounds such as zincborate or sodium borate, zinc carbonate, antimony trioxide, antimonypentoxide, sodium antimonate, sodium carbonate, antimony carbonate,aluminum carbonate, etc.; organochlorines such as chlorendic acidderivatives and chlorinated paraffins; organobromines such aspolybrominated diphenylethers, decabromodiphenyl ether,decabromodiphenyl ethane, hexabromobutene, dibromoethyldibromocyclohexane, hexabromocyclododecane, diboromoneopentyl glycol,tribromoneopentyl alcohol, brominated aliphatic polyol, polyethertriol,octabromodiphenyl ether, pentabromodiphenyl ether, fully brominateddiphenoxy benzene, decabromodiphenyl ether, octabromodiphenylether,pentabromodiphenylether, (bis-pentabromophenyl)ethane, brominatedtrimethylphenylindan, tetrabromobisphenol A, bis(tribromophenoxy)ethane,polydibromophenylene oxide, tetrabromophthalic anhydride,1,2-bis(tetrabromophthalimide)ethane, tetrabromophthalate diols,tetrabromophthalate esters, tetrabromobisphenol A, polydibromophenyleneoxide, brominated polystyrene, poly(pentabromobenzyl)acrylate, polymericbrominated compounds such as brominated polystyrenes, brominatedcarbonate oligomers, brominated epoxy oligomers, tetrabromophthalicanyhydride, tetrabromobisphenol A, hexabromocyclododecane, etc.;sulfamic acid or sulfamates; sulfamides; or organophosphorous ororganophosphate compounds such as tris(2,3-dibromopropyl)phosphate,triphenyl phosphate, tris-dichloropropyl phosphate,cresyldiphenyl phosphate, resorcinol bis(diphenylphosphate), bisphenol Abis(diphenyl phosphate), melamine phosphate, tri-o-cresyl phosphate,dimethyl methylphosphonate, phosphinates, tri-m-cresyl phosphate,tris(2-chloropropyl) phosphate, tris-(1.3-dichloro-2-propyl) phosphate,tris(chloroethyl) phosphate, trisdichloropropylphosphate, tri-p-cresylphosphate, trischloropropylphosphate, tris(chloroisopropyl)phosphate,tri(isopropylphenyl)phosphate, tetrakis(2-chloroethyl)dichloroisopentyldiphosphate, dimethyl methyl phosphonate,9,10-dihydro-9-oxa-10-phosphaphenanthrene-10-oxide,6-(2,5-dihydroxyphenyl)-6H-dibenz[c,e][1,2]oxaphosphorine-6-oxide,tetraphenyl resorcinol bis(diphenylphosphate), etc. In addition,combinations of any of these and/or other flame retardants may be used.

With reference to FIG. 3, an illustrative method of manufacturingcomposite veneer 10 of the present disclosure begins with producingwood, illustratively poplar sheets at step 42. More particularly, apoplar log is sliced to form 0.024 inch thick leaves or sheets. Halfround slicing is illustratively utilized to ensure consistency. Halfround slicing is defined as cutting on an arc roughly parallel to thecenter of a log to achieve flat-cut leaves or sheets. Next, the poplarsheets are stacked and press dried until there is between 7% to 10%moisture content. The poplar sheets are then prepared for splicing. Forexample, opposing edges of each sheet are cut in parallel.

The illustrative method continues to step 44 where the poplar sheets arespliced together to define the outer faces 12 and 14. Edges of thepreviously formed poplar sheets are spliced together, illustrativelythrough an adhesive such as urea glue. The formed outer faces 12 and 14are then visually inspected on a light table for imperfections, such asvarying thicknesses (i.e., too thick or thin), open joints, chips,and/or cracks. Faces 12 and 14 displaying such imperfections arerejected to avoid telegraphing. Next, the faces 12 and 14 are sanded,illustratively through aluminum oxide discs, to smooth glue joints. Thefaces 12 and 14 are then inspected on a light table for uneven sanding.

The illustrative method then continues at step 46 where the nonwoveninner ply 16 is prepared to press. Additional details on illustrativecompositions and methods of forming nonwoven inner ply 16 are providedabove. Initially, the inner ply 16 is visually inspected for folds andoverlaps. A light table is then used to visually inspect the inner ply16 for varying thicknesses (i.e., too thick or thin), light spots,uneven patterns, and/or debris. The inner ply 16 is then pressed forcompression and uniformity. More particularly, the inner ply 16 isplaced within a press having platens heated to a temperature of 165° F.The inner ply 16 is then pressed between the platens at 100 bars ofpressure for 10 seconds. The pressure is released and then the platensagain press the inner ply 16 at 100 bars of pressure for 15 seconds. Theinner ply 16 is then inspected for uneven pressure by measuring thethicknesses on opposing sides. Any inner ply 16 having more than 0.002to 0.003 inches variation in thickness is rejected.

The illustrative method continues to step 48 where the outer faces 12and 14 are prepared for pressing onto the inner ply 16. Moreparticularly, the faces 12 and 14 are inspected for quality andcompliance with customer specifications. The faces 12 and 14 are thensorted and stacked prior to cutting and drying. Each face 12 and 14 isthen inspected on a light table before splicing or hand taping. Faces 12and 14 are spliced together per customer specifications (e.g., outerdimensions). A further inspection is performed on a light table. Faces12 and 14 are then stacked in a temperature controlled room at 80° F.for 24 hours. Next, the faces 12 and 14 are pressed to dry. Moreparticularly, each face 12 and 14 is placed in a press between platensheated to 180° F. Each face 12 and 14 is pressed for 10 seconds withonly the weight of the platen applying pressure (i.e., no hydraulicpressure). The pressing is repeated until no steam is present from theface 12, 14 between the platens. At that point, the face 12, 14 isremoved from the press and stored at room temperature.

At method step 50, the outer face 12 is pressed to the inner ply 16 todefine a 2-ply veneer. Plies 12 and 16 are initially inspected fordebris. Next, the inner ply 16 is placed above glue line 18 which, inturn, is placed above the outer face 12. Illustratively, the glue line18 may be defined by a variety of adhesives based upon thespecifications of the outer face 12. Illustrative adhesives for glueline 18 include glues include Tego phenolic glue, 204TS phenolic glue,and 330TS acrylic melamine glue. The assembled layers 12, 16 and glueline 18 are then placed in a press with platens heated to 350° F. Thelayers 12, 16 and glue line 18 are pressed for 6 minutes, 30 seconds at230 bars of pressure. The formed 2-ply veneer is then removed from thepress and allowed to cool to room temperature.

The illustrative method then continues at step 52, where the outer face16 is pressed to the 2-ply previously formed from the outer face 12 andthe inner ply 16. The outer face 14 is placed above the glue line 20.Glue line 20 may be similar to glue line 18 identified above. The outerface 14 is next pressed to the two ply (including outer face 12 andinner ply 16). The assembled layers 12, 14, 16 and glue lines 18, 20 arethen placed in a press with platens heated to 350° F. The layers 12, 14,16 and glue lines 18, 20 are pressed for 6 minutes, 30 seconds at 230bars of pressure. The formed 3-ply veneer is then removed from the pressand allowed to cool to room temperature.

Sanding and trimming of the formed 3-ply veneer 10 occurs at step 54.More particularly, edges are pre-trimmed to remove oversized face 12, 14and inner ply 16 material. Any debris is removed and the veneer 10 isstored. The veneer 10 is then sanded to customer specifications.

The illustrative method continues to step 56, where the veneer 10 isfire treated. The veneer 10 is illustratively fire treated with a fireretardant chemical, such as TFP-III, available from Eagle PerformanceProducts of Calhoun, Ga. Each veneer sheet 10 is dipped into the fireretardant for approximately 5 minutes. The veneer 10 is then removed anddrip dried for 5 minutes. The veneer 10 is then placed in awell-ventilated room and fan dried to 10 to 14% moisture content. A 60second burn test is then performed. If the veneer 10 fails the test,then the treatment process is repeated. The veneer 10 is then allowed tosit for 24 to 48 hours before shipping to customers.

The resulting veneer sheet 10 may be produced in various dimensions,such as 48 inches by 96 inches, and 48 inches by 120 inches. Theillustrative thickness of veneer sheet 10 is 0.059 inches +/−0.005inches. The veneer sheet 10 illustratively has a mean weight of 0.213lb/ft², a tear resistance of 14.3+/−1.9 lbs., and a moisture regain of7.3%+/−0.2% at 50% humidity. The sheet 10 illustratively has a bendingradius as low as 0.20 inches parallel to wood grain, and as low as 1.25inches perpendicular to wood grain. The sheet 10 meets flammabilityrequirements per FAR 25-853(a), 14 CFR 25.853(a) App. F Part 1(a)(1)(i):60 second vertical impingement.

The flexural modulus of an illustrative sample of a cherry veneerincluding a novoloid nonwoven inner ply was compared to that of atypical 3-ply cherry veneer with a poplar cellulose inner ply. Thetesting was conducted per ASTM D790-97 on a 6″ by 1″ sample in both themachine direction (MD) and cross-machine direction (XD). The results arepresented in Table 1.

TABLE 1 Flexural Modulus Results Modulus of Elasticity N/mm² Non-woveninner ply MD 3277.2 Typical 3-ply MD 16631.5 Non-woven inner ply XD443.5 Typical 3-ply XD 1947.8

As shown in Table 1, the non-woven inner ply containing sampleillustratively has a flexural modulus about 5.1 times lower than thetypical 3-ply sample in the machine direction and about 4.5 times lowerin the cross-machine direction.

Although the invention has been described in detail with reference tocertain preferred embodiments, variations and modifications exist withinthe spirit and scope of the invention as described and defined in thefollowing claims.

1. A composite veneer including: a first cellulose face; a secondcellulose face in parallel spaced relation to the first cellulose face;and a nonwoven inner ply positioned intermediate the first celluloseface and the second cellulose face, the nonwoven inner ply formed from aplurality of polymer fibers.
 2. The composite veneer of claim 1, whereinthe polymer fibers are formed of an at least partially amorphouspolymer.
 3. The composite veneer of claim 1, wherein the polymer fibersare formed of a novoloid.
 4. The composite veneer of claim 1, whereinthe polymer is selected from the group consisting of: polystyrene,polymethylmethacrylate, polyphene sulfides, polysulfone, polyetherimide,polyetheretherketone, polyether sulfone, polyisobutylene, poly(vinylacetate), and novoloid.
 5. The composite veneer of claim 1, wherein thepolymer fibers are formed of a polymer selected from the groupconsisting of: nylon, novoloid, novolac, phenolic fibers, melamines,polyesters, polypropylenes, polyethylenes, polystyrenes, polyacrylicacids, polyacrylonitrils, polyimides, polyetherimides, polyamideimides,polymethyl methacrylates, polyphenelene sulfides, aramids,polybenzimidazoles, polyphenylenebenzobizoxazoles, aromatic polyketones,polyvinyl acetates, polysulfones, polyethersulfones, polyurethanes,polyisobutylenes, liquid crystal polymers, and poly(paraphenyleneterephthalamide).
 6. The composite veneer of claim 1, wherein the innerply further comprises a synthetic latex.
 7. The composite veneer ofclaim 1, wherein the inner ply further includes a flame retardant. 8.The composite veneer of claim 1, wherein the composite veneer has a zerosecond extinguish rate after burn.
 9. The composite veneer of claim 1,wherein the nonwoven inner ply is a needle punched nonwoven material.10. The composite veneer of claim 1, wherein the first cellulose faceand the second cellulose face are formed of poplar wood.
 11. Thecomposite veneer of claim 1, further including: a first adhesive layerbetween the first cellulose face and the nonwoven inner ply; and asecond adhesive layer between the nonwoven inner ply and the secondcellulose face.
 12. The composite veneer of claim 11, wherein the firstand second adhesive layers independently comprise an adhesive selectedfrom the group consisting of: a phenolic glue and an acrylic melamineglue.
 13. The composite veneer of claim 1, wherein the composite veneerhas a flexural modulus at least about 4 times lower than similarlyconstructed three-ply veneer having a cellulose inner ply.
 14. Thecomposite veneer of claim 1, wherein the composite veneer has a bendingradius of about 0.20 inches parallel to a wood grain of the first andsecond cellulose faces.
 15. A method of forming a composite veneer, themethod comprising: providing a first cellulose face; providing anonwoven ply formed from a plurality of polymer fibers; adhering thenonwoven ply to the first cellulose face with a first glue line;pressing the first cellulose face, first glue line, and nonwoven ply ina press at elevated temperature and pressure to form a two plycomposite; adhering a second cellulose face to the nonwoven ply of thetwo ply composite with a second glue line; and pressing the two plycomposite, second glue line, and second cellulose in a press at elevatedtemperature and pressure to form the composite veneer.
 16. The method ofclaim 15, further comprising: slicing a log to form a plurality ofsheets; splicing a first portion of the plurality of sheets with anadhesive to form the first cellulose face; and splicing a second portionof the plurality of sheets with an adhesive to form the second celluloseface.
 17. The method of claim 15, further comprising pressing thenonwoven ply at an elevated temperature and pressure.
 18. The method ofclaim 15, further comprising treating the composite veneer with a fireretardant.
 19. The method of claim 15, wherein the polymer fibers areformed of a novoloid.
 20. The method of claim 15, wherein the elevatedtemperature is about 350° F. and the elevated pressure is about 230 bar.